Yarn with heat-activated binder material and process of making
Yarn suitable for tufting comprises a base fiber ring spun or wrap spun with a second fiber at least partially comprising a heat-activated adhesive material such that the yarn includes from 0.1 to 12, preferably 0.25 to 10, weight percent adhesive material having a melting point within the range of 105° to 190° C, more preferably 165° to 190° C. A preferred base fiber is a synthetic staple fiber bundle. A preferred wrapping or insert fiber comprises copolyamide material, including ternary copolyamides of the 6/66/12 type. When the yarn is twist set by conventional processes and then tufted into carpet, the resulting carpet displays enhanced wear and appearance properties.
1 . A wrap spun yarn produced by a process comprising the steps of:
a. forming a bundle of fiber;
b. wrap spinning the bundle of fiber with a second fiber comprising a heat-activated binder material having a melting point range of about 105° to 190° C. under ambient conditions to form a yarn;
c. twisting two or more of the yarns to form a plied yarn comprising 0.1 to 12 weight percent of the binder material;
d. heating the plied yam sufficiently to melt the binder material; followed by
e. cooling the plied yarn to solidify the binder material.
2 . The wrap spun yam of claim 1 wherein said heating step occurs during twist setting of the plied yarn.
3 . The wrap spun yarn of claim 1 wherein the bundle of fiber is formed by spinning staple fiber.
4 . (canceled)
5 . (canceled)
6 . (canceled)
7 . (canceled)
8 . The wrap spun yarn of claim 1 wherein the bundle of fiber is formed by spinning staple fiber.
9 . (canceled)
10 . The wrap spun yam of claim 1 wherein the twisting is ply twisting and wherein the yarns are wound with the second fiber(s) to form an assembly wound package to provide the feed yarns for ply twisting.
11 . The wrap spun yam of claim 1 wherein said heating step occurs during twist setting of the plied yarn.
12 . The wrap spun yarn of claim 1 wherein the bundle of fiber is formed by spinning staple fiber.
13 . (canceled)
14 . The wrap spun yarn of claim 1 wherein the fiber is nylon-6 having melt point range of 215 to 225° C.
15 . The wrap spun yarn of claim 1 wherein the bundle comprises a first base fiber is selected from the group consisting of a sliver and a bundle of continuous filaments.
16 . The wrap spun yarn of claim 1 wherein said fiber is a polyamide selected from the group consisting of nylon-6 and nylon-6,6.
17 . The wrap spun yarn of claim 1 wherein said second fiber comprises a copolyamide.
18 . The wrap spun yarn of claim 1 wherein said second fiber comprises a copolyamide of nylon 6/nylon 6,6 or nylon6/nylon 6,6/nylon 12.
19 . The wrap spun yarn of claim 1 wherein said fiber is a polyamide and said second fiber comprises a copolyamide.
20 . The wrap spun yarn of claim 1 wherein said fiber is a polyamide selected from the group consisting of nylon-6 and nylon-6,6 and wherein said second fiber comprises a copolyamide of nylon 6/nylon 6,6 or nylon6/nylon 6,6/nylon 12.
21 . The wrap spun yarn of claim 1 wherein said second fiber(s) comprises a heat-activated binder material having a melting point of about 165 to 190° C.
22 . A ring spun yarn produced by a process comprising the steps of:
a. forming a bundle of fiber;
b. ring spinning the bundle of fiber with a second fiber comprising a heat-activated binder material having a melting point range of about 105° to 190° C. under ambient conditions to form a yarn;
c. twisting two or more of the yarns to form a plied yarn comprising 0.1 to 12 weight percent of the binder material;
d. heating the plied yarn sufficiently to melt the binder material; followed by
e. cooling the plied yarn to solidify the binder material.
23 . The ring spun yarn of claim 22 wherein said heating step occurs during twist setting of the plied yarn.
24 . The ring spun yarn of claim 22 wherein the bundle of fiber is formed by spinning staple fiber.
25 . The ring spun yarn of claim 22 wherein the bundle of fiber is formed by spinning staple fiber.
26 . The ring spun yarn of claim 22 wherein the twisting is ply twisting and wherein the ring spun yarns are wound with the second fiber(s) to form an assembly wound package to provide the feed yarns for ply twisting.
27 . The ring spun yarn of claim 22 wherein said heating step occurs during twist setting of the plied yarn.
28 . The ring spun yarn of claim 22 wherein the bundle of fiber is formed by spinning staple fiber.
29 . The ring spun yarn of claim 22 wherein the fiber is nylon-6 having melt point range of 215 to 225° C.
30 . The ring spun yarn of claim 22 wherein the bundle comprises a first base fiber is selected from the group consisting of a sliver and a bundle of continuous filaments.
31 . The ring spun yarn of claim 22 wherein said fiber is a polyamide selected from the group consisting of nylon-6 and nylon-6,6.
32 . The ring spun yarn of claim 22 wherein said second fiber comprises a copolyamide.
33 . The ring spun yarn of claim 22 wherein said second fiber comprises a copolyamide of nylon 6/nylon 6,6 or nylon6/nylon 6,6/nylon12.
34 . The ring spun yarn of claim 22 wherein said fiber is a polyamide and said second fiber comprises a copolyamide.
35 . The ring spun yarn of claim 22 wherein said fiber is a polyamide selected from the group consisting of nylon-6 and nylon-6,6 and wherein said second fiber comprises a copolyamide of nylon 6/nylon 6,6 or nylon6/nylon 6,6/nylon 12.
36 . The ring spun yarn of claim 22 wherein said second fiber(s) comprises a heat-activated binder material having a melting point of about 165 to 190° C.